Slide Opening Box with Integral Liner

ABSTRACT

A box with a sliding opening has an integral liner to keep pourable contents fresh and dry. The box has a slide that is moveable by a user&#39;s thumb across the opening to open and close the box and the liner during the same operation. The user in one motion can either open the box and the liner to pour out the contents or close the box and the liner so the contents do not spill out. Advantageously, the box is formed from a single blank piece of paper or cardboard stock, and a single planar sheet of moisture impervious material liner is placed onto the blank and folded in a particular sequence such that the slide ends up inside the box for easy assembly with a resulting sealed liner bag inside.

BACKGROUND

The present disclosure relates to packaging for pourable materials, andin particular, to a box with a slide opening and an integral liner forcontaining and dispensing pourable items such as cereal or otherfoodstuffs.

A wide range of pourable products such as dry cereals, powdered laundrysoap and many others are dispensed in cardboard boxes. To access thecontents, a user must generally open the top of the box. Sometimes thecontents are held in a wax paper or other plastic-type bag inside thebox and that bag must be torn open after opening the box. To storecontents and maintain their freshness or dryness and limit exposure tohumid ambient air, a user folds over the bag to close the bag and closesthe box when possible which typically has an awkward, difficult tomanipulate closure, particularly in the case of traditional breakfastcereal boxes.

Standard cereal boxes are typically delivered in a tube-shaped standardfolding carton, partially assembled and collapsed condition. Whenmanufacturing boxes in large quantities, e.g. for mass distributedbreakfast cereals, it is preferable to have the box delivered to theend-manufacturer as a folded flat. Automated machinery at the foodprocessor opens up the flat carton, folds and secures top or bottomflaps to form a box with an open end. Next the machinery fills the boxwith product, and the box is closed to complete packaging.

Applicant has developed packages of new and differing functionalitywhich offer significant improvements in dispensing product yetmaintaining the processing same as standard folding cartons withconventional high speed machinery, over the prior art. Applicant is thenamed inventor on numerous U.S. patents directed to specialty packagingincluding U.S. Pat. Nos. 6,116,499, 6,273,332, 6,360,942, 6,435,402,6,945,449, 7,040,528, 7,156,286 and 7,743,973, and application Ser. No.12/686,252 filed Jan. 12, 2010. These patents and the pendingapplication show the progression of Applicant's innovative packagingdesigns, and how they have evolved to become friendlier to thehigh-speed form, fill, and seal machines used by major food processingcompanies in producing hundreds of packages per minute.

While Applicant's packages described in existing patents offer manyadvantages over the prior art, there remains a need for a massproducible box with a sealed bag inside, for storing and maintaining therequired liner by cereal MFG companies, while providing dispensingportions of the contents and re-closing the box with ease. The needexists for a box for containing pourable items where the liner bag isconveniently constructed along with the box, and a liner bag insidewhich can be opened and closed as the box is opened and closed by aconvenient slide opener.

SUMMARY

A box having an integral liner containing pourable items, and a methodof packaging and dispensing pourable products, such as cereal, isdisclosed. A box having an integral liner is formed from a foldable boxblank. The foldable box blank has a plurality of sides coupled together,each of the sides corresponding to a side of the box when folded. In oneembodiment, the foldable box blank is preferably made of cardboardmaterial.

A first side of the box blank has a side opening, which serves as theopening through which pourable product will be dispensed. Coupled to thefirst side opening, a slide allows the box to be opened and closed whenthe package is used. It is anticipated that the slide may be coupled tothe first side prior to assembly, and in this manner, the package may beconstructed specifically from a single flat piece of box blank stock.Alternatively, the side opening can be located virtually anywhere on thebox convenient for pouring.

As freshness is a desired characteristic of goods contemplated to bedispensed from the box, a bag substantially sealed inside the box iscontemplated as part of the package. In one exemplary embodiment, thebag may be made from a moisture impervious material, including aheat-sealable plastic-type material known to skilled persons formaintaining the freshness and dryness of contained items, or anymaterial which satisfies these purposes. Typically the moistureimpervious material substantially covers the box blank prior to assemblyof the package. The moisture impervious material has a perforatedportion, defining an opening, overlaying the side opening of the box,which may be sealed together. By sealing the openings of the box andbag, a substantially air-tight re-sealable package is produced. Theunion of the openings also prevents product or other material fromlodging between the bag and box.

Once the box blank and moisture impervious material have been foldedinto the box and bag, respectively, forming the package, product may beintroduced into the package. It is anticipated that product may beintroduced during the folding process by leaving one side, in oneembodiment a top or bottom side, open for the introduction of product.Once product is introduced into the package, the remaining side may beclosed, sealing the package until opened by a user. Glue or a similaradhesive may also be used to attach selected portions of the bag,notably around the opening, to the box blank. Using the integral lineralso eliminates the empty corners found in conventional cereal boxeswith bags, and thus makes it possible for manufacturers to use smallerboxes saving on paper and the environment.

Completing the method, to use the package, a user moves the slideopening to expose the bag inside the box. In one embodiment, it isanticipated the slide will have a first portion adapted to slide alongthe first side of the box, and a second portion adapted to extend awayfrom the box top. It is also anticipated that the slide may comprise atab allowing a user to actuate the slide more easily. In an alternativeembodiment, a removable patch (not shown) may also be sealed over theperforated portion.

Upon first use of the slide, the box opening is exposed along with thesection of the bag to be opened. A user may remove the section of thebag, which is typically surrounded by perforations, to access theproduct. In addition to the perforated opening being located overlayingthe box opening, in one embodiment, a tab may be present adjacent theperforated portion of the bag to facilitate removal. Once the portion ofthe bag surrounded by perforations is removed, with the slide in an openconfiguration, product may be poured through the side opening.

Once a desired amount of pourable product is dispensed from the box, auser may move the slide to a position covering the side opening and theopening in the bag, which will close the box and bag with one movement.Without further actions by the user such as folding over the bag orclipping it closed, freshness of the pourable product in the packagewill be preserved. Due to the position of the opening on the side of thebox and tabbed slide, the slide may be engaged with a user's thumb inone embodiment. In order to prevent the portion of the slide coveringthe opening from dislocating from the box, the slide may be equippedwith one or more stops adapted to limit sliding movement of the slide.

In one alternative embodiment, it is anticipated that the sheet ofmoisture impervious material may be in a folded condition prior to thesteps of sealing opposing edges of the moisture impervious material toform a bag and attaching the bag to the box blank. In this embodiment,the folded sheet of moisture impervious material also has an openingdefined by perforations adapted to overlay the side opening. It isanticipated that the method of use of the assembled package in thisembodiment will be substantially the same as in other embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a flat pattern view of the blank from which an embodiment ofthe box is made.

FIG. 2 is a perspective view of the blank and the liner material adaptedto cover the blank, also showing an initial assembly step.

FIG. 3 is a perspective view of the blank and liner material, alsoshowing subsequent assembly steps.

FIG. 4 is a plan view of the partially assembled box showing the liftingflap in one embodiment of the invention and a portion of the linermaterial cut away for clarity of illustration.

FIG. 5 is a front perspective view of the box showing assembly of thelifting flap and hidden components of the lifting flap in dashed line.

FIG. 6 is a front perspective view of the box showing the lifting flapin a closed configuration.

FIG. 7 is an inverted front perspective view of the box being filledfrom the bottom with pourable product.

FIG. 8 is a front perspective view of the box showing operation of theslider and lifting flap.

FIG. 9 is a perspective view of an alternative embodiment of theinvention showing a liner separate from a blank having adhesive areas.

FIG. 10 is a perspective view of a liner folded and adhered to a blankby compression, and hot rollers sealing edges of the liner forming abag.

FIG. 11 is a front perspective view of the box showing the sealed baginside the box prior to closing the box bottom.

FIG. 12 is a front perspective view of the box prior to filling andclosing the box.

FIG. 13 is an inverted front perspective view of the box being filledfrom the bottom with pourable product.

FIG. 14 is an inverted front perspective view of the bottom of the bagbeing hot sealed prior to closing.

DESCRIPTION

FIG. 1 illustrates one embodiment of a die cut paper or cardboard blank10 that may be used to form the box 12. The blank 10 has a top end 14and a bottom end 16 and is scored for folding between a first minor side18, a first major side 20, a second minor side 22 and a second majorside 24, all generally rectangular in shape. The first minor side 18includes flap 26 and aperture 28 and is attached to the first major side20 by fold line 30. The first major side 20 includes major flaps 32 and34 and is connected to second minor side 22 by fold line 36. The secondminor side 22 includes flaps 38 and 40 and is connected to second majorside 24 by fold line 42. The second major side 24 includes flaps 44 and46 and is connected to the overlapping flap or manufacturer's joint 48(which includes aperture 49) by fold line 50.

Still referring to FIG. 1, the slider retention portion 52 is attachedto the first minor side 18 along fold lines 54 and 56 with a slottedopening 58. The slider retention portion 52 is formed with aperture 60and includes the stopper tabs 62 and 64 and a minor flap 65. The sliderretention portion 52 is attached to the slider 66 along perforated lines68 and 70. The slider 66 includes the slide 72 which is connected alongfold lines 76 and 78 to the lifting flap 74 and includes the tab 80configured for engagement by a user's thumb when folded, and smallcutouts 81 in the minor sides 18, 22, and 48 to provide easy access tothe tab 80. The lifting flap 74 is attached to the attachment portion 82along fold line 84. The slider 66 is formed with aperture 90 andincludes tabs 86 and 88. The minor flaps 26, 38, 40 rather than beingentirely separated from the major flaps 32, 34, 44, and 46 have insteada line of weakness or are perforated. Additionally, the minor flaps 26,38, 40, and 65 have a fold line 67 the function of which is explainedbelow.

FIG. 2 illustrates an embodiment with the liner 100 shown prior to beingaffixed to the blank 10. The liner 100 includes an opening 112 and aliner flap 102. The liner flap 102 is attached to a connector portion106 connecting it with the liner 100 and removable liner portion 104.The liner 100 is connected to the removable liner portion 104 with aperforation line 104 a. As can be appreciated from FIG. 2, pulling flap102 away from the liner 100 removes the removable liner portion 104along perforation line 104 a. The liner 100 is preferably made of aplastic, waxed paper, or other materials known to persons skilled in theart for containing pourable items in a box in a fresh or dry state. Theapertures, 28, 49, 60, and 90, and liner opening 112 are all compatiblein shape, although not necessarily the same shape, such that when thefour openings are aligned as discussed herein, a path is provided fromthe interior of the box to the exterior.

Still referring to FIG. 2, construction of the box 12 begins withfolding the slider 66 over onto the slider retention portion 52 alongperforated lines 68, 70. Referring to FIG. 3, the overlapping slider 66and slider retention portion 52 are then folded over onto minor side 18along fold line 56. The liner 100 is then affixed to the blank 10 andglued or otherwise adhered to the blank 10 to secure the liner 100thereto such that the liner opening 112 is placed substantially inalignment with aperture 28 of the first minor side 18. As shown in FIG.4, in one embodiment, the liner 100 extends about a half inch (0.5 in.)beyond the top end 14, the bottom end 16, and about that same distanceinto the overlapping flap 48 and extending over onto portions of sliderretention portion 52 and the slider 66. In one embodiment a series ofsmall glue dots, not shown, are deposited on the blank 10, particularlynear the aperture 28 to ensure proper alignment is maintained, as wellas across the remainder of the blank 10.

To continue box assembly, the slide 72 is situated between the sliderretention portion 52 and the liner 100 with the slide 72 incommunication with the liner flap 102. Further, the overlapping flap 48is folded along fold line 50 so that it is approximately perpendicularto second major side 24 and then similarly folding between second majorside 24 and second minor side 22 along fold line 42, folding betweensecond minor side 22 and first major side 20 along fold line 36 and thenfolding between first major side 20 and first minor side 18 along foldline 30. The overlapping flap 48 is then glued or otherwise adhered tothe first minor side 18 to form a generally rectangular box 12 as shownin FIG. 5.

FIG. 6 shows the box 12 further assembled with flaps 32, 44 and 38folded over and glued or otherwise adhered together to close the top ofthe box 12. The lifting flap 74 is also folded over onto the foldedflaps 32 and 44 with the attachment portion 82 glued or otherwiseadhered thereto. FIG. 6 also shows the tab 80 on the lifting flap 74.

FIG. 7 shows the box 12 being filled from the bottom with pourableproduct prior to final assembly, which is one method of filling theassembled box 12. Final assembly of the box 12 is accomplished byfolding over flaps 26 and 40, and then flaps 46 and 34, which are thenglued or otherwise adhered together to close the bottom of the box 12 tohold the pourable product. As mentioned above, flaps 26 and 40 may bescored with fold lines 67, which helps retain all the cereal or otherproduct and prevents dust or small particles of product from beingreleased from the box as it is closed. Assembling the package in thismanner creates a box with a sealed, air-tight liner bag inside to keepthe cereal or other pourable product dry and fresh.

FIG. 8 shows a manner of dispensing pourable product from the box 12following removal of the liner cover 104 from the liner 100. The tab 80is lifted by a user's thumb in the direction of the arrow 120 to movethe slide 72 upward to align the aperture 90 with the aperture 28 on thefirst minor side 18. The stopper members 62, 64 prevent advance of theslide 72 beyond the first minor side 18 by engaging the tabs 86, 88 onthe slide 72. The liner opening 112 is created by pulling the liner flap102. The pourable product within the box 12 is then dispensed from thebox 12 through the liner opening 112 and out through apertures 90 and28. Pushing down on the tab 80 in the opposite direction of the arrow120 moves the slide 72 back down to close the aperture 28 and also toclose the liner opening 112.

In some embodiments, it may be preferable to prepare the liner 100 andblank 10 for assembly by passing the blank 10 and liner 100 through hotrollers or other sealing apparatus under pressure. Referring to FIGS.9-14, an alternative method of forming and attaching the liner 100 andassembling the box 12 is shown. In FIG. 9, the liner 100 is folded alongfold line 36 as the overlapping slider 66 and slider retention portion52 are folded over onto minor side 18 along fold line 56 (See, FIG. 3).

Adhesive strips 114 incorporated onto the surface of the unassembledblank 10 are designed to hold the liner 100 in position as the blank 10is folded into a three-dimensional box 12. Although adhesive strips arecontemplated, alternative embodiments may employ adhesive in spots, notshown, across predetermined portions of the box blank, or in anotherconfiguration to support the bag in position.

Referring to FIG. 10, with the liner 100 folded over the blank 10, hotpressure is applied to seal the liner 100. In one embodiment, the liner100 may be passed through a hot rolling mechanism.

As shown in FIG. 11, the liner 100 is glued and closed proximal the topof the box prior to assembly of the flaps 32, 44, and 38, which arefolded over and glued or otherwise adhered together to close the top ofthe box 12, along with the lifting flap 74 which is folded over onto thefolded flaps 32 and 44 with the attachment portion 82 glued or otherwiseadhered thereto (See FIGS. 5-6). In this manner of assembly, in onealternative embodiment, the side of the liner 100 adjacent the bottom ofthe blank 10 is left unsealed. In one embodiment, due to adhesion withthe blank 10, as the blank 10 is folded into a three dimensional box,the liner 100 at the bottom of the box 12 opens to accommodate pourableproduct as shown in FIG. 12.

Referring to FIGS. 13 and 14, pourable product is introduced into thebox 12 in the same manner as the embodiment shown in FIG. 7. In thisembodiment, the liner 100 is not adhered to flaps 26, 40, 34, and 46prior to introduction of the pourable product. Rather, the product isintroduced into the box 12, and thereafter a hot roller or othermechanism is brought to bear against the liner 100, to seal it. Once theliner 100 is sealed, flaps 26, 40, 34 and 46 are closed to create anassembled box 12 having a pourable product contained by a sealed liner100 therein.

While particular forms of the invention have been illustrated anddescribed, it will also be apparent to those skilled in the art thatvarious modifications can be made without departing from the spirit andscope of the invention. Accordingly, it is not intended that theinvention be limited except by the full breadth and scope of theappended claims.

1. A method of packaging and dispensing pourable product comprising thesteps of: forming a box blank having a plurality of sides coupledtogether, a first side having a side opening and coupled to a slidecovering the side opening; attaching moisture impervious material tosubstantially cover the box blank, the moisture impervious materialhaving an opening overlying the side opening; forming the box blank intoa box with the attached moisture impervious material forming a baginside the box; introducing the product into the bag; selectively movingthe slide uncovering the side opening and the opening in the moistureimpervious material, thereby opening the box and the bag with onemovement; and dispensing the pourable product through the side openingand the opening in the moisture impervious material.
 2. The method ofclaim 1 further comprising the step of selectively moving the slidecovering the side opening and the opening in the bag, thereby closingthe box and the bag with one movement.
 3. The method of claim 1 furthercomprising the step of removing a removable portion of the moistureimpervious material to form the opening in the bag.
 4. The method ofclaim 1 further comprising the step of engaging a tab on the slide witha user's thumb.
 5. The method of claim 1 further comprising the step ofmoving the slide against at least one stop member limiting slidingmovement of the slide.
 6. The method of claim 3 further comprising thestep of perforating the bag to create the removable portion.
 7. A methodof packaging and dispensing pourable product comprising the steps of:forming a box blank having a plurality of sides coupled together, afirst side having a side opening and coupled to a slide covering theside opening; folding a sheet of moisture impervious material; sealingopposing edges of the sheet together forming a bag; attaching the bag tothe box blank, the bag having an opening overlying the side opening;forming the box blank into a box; introducing the product into the bag;selectively moving the slide uncovering the side opening and the openingin the bag, thereby opening the box and the bag in one movement; anddispensing the pourable product through the side opening arid theopening in the bag.
 8. The method of claim 7 further comprising the stepof removing a removable portion of the moisture impervious material toform an opening in the bag.
 9. The method of claim 7 further comprisingthe step of engaging a tab on the slide with a user's thumb.
 10. Themethod of claim 7 further comprising the step of moving the slideagainst at least one stop member limiting sliding movement of the slide.11. The method of claim 7 further comprising the step of perforating thebag to create a removable portion.
 12. The method of claim 7 furthercomprising the step of applying an adhesive to predetermined portions ofthe box blank for attaching the bag.
 13. A package for dispensingpourable product comprising: a box blank having a plurality of sidesfoldably coupled together, and a first side having a side openingcoupled to a slide for covering the side opening; a sheet of moistureimpervious material adapted to cover a substantial portion of the boxblank, the moisture impervious material having a perforated portion ofthe moisture impervious material overlying the side opening; an adhesivefor securing a portion of the moisture impervious material to the boxblank; wherein the moisture impervious material is adhered to the boxblank, and forms a bag when the blank is folded into the package. 14.The package of claim 13 wherein the slide is foldably coupled to a tabconfigured to be engaged by a user's thumb for ease in selectivelymoving the slide.
 15. The package of claim 13 wherein the slide has atleast one stop member to limit movement of the slide so the slideremains proximate the side opening.